Print media manufacturing system

Abstract

A print media manufacturing system including a print media conveyor, a plurality of print media processing machines adapted to dispense print media components to the print media being conveyed on the print media conveyor, an automated storage and retrieval machine including a shuttle, and a storage rack that stores reserve supply of print media components used by the plurality of print media processing machines. The storage and retrieval machine is operable to position the shuttle along the storage rack, and the shuttle is operable to enter the storage rack to retrieve the reserve supply of print media components stored therein, and to deliver the retrieved reserve supply to the print media processing machines.

1 . A print media manufacturing system comprising: 
 a print media conveyor for conveying print media thereon;    a plurality of print media processing machines positioned along said print media conveyor, said print media processing machines being adapted to dispense print media components to said print media conveyor;    at least one supply rack positioned proximate to said plurality of print media processing machines, said at least one supply rack receiving supplies of print media components used by said plurality of print media processing machines;    a rail positioned substantially parallel to said at least one supply rack;    an automated storage and retrieval (S/R) machine including at least one shuttle that is operable to move in a direction perpendicular to said rail, said S/R machine engaging said rail to allow said S/R machine to travel substantially parallel to said at least one supply rack; and    at least one storage rack that stores reserve supply of print media components used by said plurality of print media processing machines, said at least one storage rack being positioned adjacent to said rail so that said rail is positioned between said at least one supply rack and said at least one storage rack;    wherein said S/R machine is operable to position said shuttle along said at least one storage rack, and said shuttle is operable to enter said at least one storage rack to retrieve said reserve supply of print media components from said at least one storage rack.    
   
   
       2 . The system of  claim 1 , wherein said S/R machine is operable to position said shuttle along said at least one supply rack, and said shuttle is operable to deliver said retrieved reserve supply of said print media components.  
   
   
       3 . The system of  claim 2 , wherein said shuttle includes drive wheels and a means for lifting said reserve supply of print media components onto said shuttle, said drive wheels being operable to move in a synchronized manner with said means.  
   
   
       4 . The system of  claim 1 , further including a programmable controller that controls the operation of said S/R machine and said shuttle.  
   
   
       5 . The system of  claim 1 , wherein said at least one storage rack includes a plurality of vertically arranged storage bays for storing said reserve supply of print media components.  
   
   
       6 . The system of  claim 5 , wherein said S/R machine further includes a vertically extending mast and a vertically movable carriage to elevate said shuttle for entry into said plurality of vertically arranged storage bays to retrieve said print media components stored therein.  
   
   
       7 . The system of  claim 6 , wherein said plurality of vertically arranged storage bays include a plurality of overhead storage bays positioned above said at least one supply rack, said shuttle being operable to enter into said plurality of overhead storage bays to retrieve said print media components stored therein.  
   
   
       8 . The system of  claim 7 , wherein said plurality of overhead storage bays are also positioned above said plurality of print media processing machines.  
   
   
       9 . The system of  claim 8 , wherein said plurality of overhead storage bays are also positioned above said print media conveyor.  
   
   
       10 . The system of  claim 1 , wherein said plurality of print media processing machines dispense one print media component at a time.  
   
   
       11 . The system of  claim 10 , wherein said print media components are signatures of at least one of a book, a magazine, and a catalog.  
   
   
       12 . The system of  claim 11 , further including at least one binding machine that binds said signatures together by at least one of stapling and gluing said signatures together.  
   
   
       13 . The system of  claim 10 , wherein said print media components are inserts for a newspaper, and said plurality of print media processing machines include a plurality of inserting machines that dispense said inserts into said newspaper.  
   
   
       14 . The system of  claim 10 , wherein said print media components are different magazine titles, and said plurality of print media processing machines include a plurality of collating machines that stack magazines together.  
   
   
       15 . The system of  claim 1 , wherein said print media conveyor is elevated relative to said rail.  
   
   
       16 . The system of  claim 1 , wherein said at least one supply rack includes a plurality of supply bays, each supply bay being positioned proximate to one of said plurality of print media processing machines for receiving supplies of a print media component that is dispensed by said one of said plurality of print media processing machines.  
   
   
       17 . The system of  claim 1 , further including a second plurality of print media processing machines, a second supply rack positioned proximate to said second plurality of print media processing machines, a second rail positioned substantially parallel to said second supply rack, a second S/R machine with at least one shuttle, and a second storage rack positioned adjacent to said second rail, wherein said shuttle is operable to enter said second storage rack to retrieve a reserve supply of print media components stored therein.  
   
   
       18 . The system of  claim 17 , wherein said second storage rack includes a plurality of vertically arranged storage bays, and said S/R machine further includes a vertically extending mast and a vertically movable carriage to elevate said shuttle for entry into said plurality of vertically arranged storage bays.  
   
   
       19 . A print media manufacturing system comprising: 
 a print media conveyor for conveying print media thereon;    a plurality of print media processing machines positioned along said print media conveyor, said print media processing machines being adapted to dispense print media components to said print media conveyor;    a supply rack positioned proximate to said plurality of print media processing machines, said supply rack receiving supplies of print media components used by said plurality of print media processing machines;    a rail positioned substantially parallel to said supply rack;    a storage rack with a plurality of vertically arranged storage bays for storing reserve supply of said print media components used by said plurality of print media processing machines, said storage rack including a plurality of vertically arranged storage bays and being positioned adjacent to said rail so that said rail is positioned between said supply rack and said storage rack;    an automated storage and retrieval (S/R) machine engaging said rail to allow said S/R machine to travel substantially parallel to said supply rack, said S/R machine including a shuttle, a vertically extending mast, and a vertically movable carriage;    wherein said S/R machine is operable to position said shuttle along said storage rack, to retrieve said reserve supply of print media components stored therein using said shuttle, to position said shuttle along said supply rack, and to deliver said retrieved reserve supply of print media components thereto using said shuttle.    
   
   
       20 . The system of  claim 19 , further including a programmable controller that controls the operation of said S/R machine and said shuttle.  
   
   
       21 . The system of  claim 19 , wherein said plurality of vertically arranged storage bays include a plurality of overhead storage bays positioned above said at least one supply rack, said shuttle being operable to enter into said plurality of overhead storage bays to retrieve said print media components stored therein.  
   
   
       22 . The system of  claim 19 , wherein said shuttle includes drive wheels and a means for lifting said reserve supply of print media components onto said shuttle, said drive wheels being operable to move in a synchronized manner with said means.  
   
   
       23 . A print media manufacturing system comprising: 
 a print media conveyor for conveying print media thereon;    a plurality of print media processing machines positioned along said print media conveyor, said print media processing machines being adapted to dispense print media components to said print media conveyor;    an automated storage and retrieval (S/R) machine including at least one shuttle, said S/R machine being adapted to travel substantially parallel to said print media processing machines; and    at least one storage rack that stores reserve supply of print media components used by said plurality of print media processing machines;    wherein said S/R machine is operable to position said shuttle along said at least one storage rack, and said shuttle is operable to enter said at least one storage rack to retrieve said reserve supply of print media components from said at least one storage rack, and deliver said retrieved reserve supply of print media components to said plurality of print media processing machines.